Masonry spacer and aligner

ABSTRACT

The Masonry Spacer and Aligner allows the brick, block or stone mason to quickly, economically and accurately position and to properly align similar masonry structural elements (for example, but not limited to: bricks, blocks, or stones) in 6-dimensions—and to do this with no lasting, visible indication that a spacing and aligning device was used. The Masonry Spacer and Aligner also creates a stronger, but more flexible, masonry structure. 
     When a sufficient number of Masonry Spacer and Aligners are used together, they properly, rapidly, neatly, and precisely position masonry structural elements vertically and horizontally in the x, y, and z axes; and, simultaneously, also properly and precisely align the masonry structural elements rotationally about the x, y and z axes. This precise, and rapid 6-dimensional positioning eliminates the necessity for repetitive, time-consuming, checking and re-positioning of masonry structural elements using sensitive, and cumbersome, positioning guides, and various alignment and leveling tools.

BACKGROUND 1. Field of the Invention

This invention relates to the laying of masonry structural elements (such as, but not limited to: bricks, concrete blocks, and stone),

and also, but not exclusively, to devices which properly separate (that is, properly “space apart”) masonry structural elements from other similar masonry structural elements within the same constructed masonry structure (for example: bricks comprising a wall or decorative masonry fascia), and also, but not exclusively, to devices which properly position the masonry structural elements, and also, but not exclusively, to devices which properly align the masonry structural elements.

SUMMARY

In order to quickly, easily, economically, and accurately position similar masonry structural elements (for example, but not limited to: bricks, blocks, or stones) in 6-dimensions, the Masonry Spacer and Aligner is useful.

In one depicted embodiment of many possible envisioned embodiments, the Masonry Spacer and Aligner consists of, and is defined by, a device depicted in FIG. 1 which:

-   -   (i) has a 2-dimensional “end shape”, formed in the         x-y-coordinate plane, and where the extremities of that “end         shape” collectively form a “circumscribing virtual shape”. In         the depicted embodiment this shape is a square, and     -   (ii) has the 3-dimensional “main body” shape created when the         “end shape” is extrapolated into the z-axis dimension. In the         depicted embodiment there is an optional hole in a portion of         the extrapolation, and     -   (iii) in the depicted embodiment, has an optional alignment         appendage which is larger, in the y-axis-dimension, than the         “circumscribing virtual shape”, and     -   (iv) in the depicted embodiment, has the alignment appendage         attached to the end of the “main body” at two small regions, and     -   (v) in all embodiments employing an alignment appendage, the         small attachment region(s) has a contact surface area which         provides only sufficient retention force and rigidity to attach         the alignment appendage to the “main body” while an additional         masonry structural element is being placed in the unset mortar,         and whereby the small attachment region(s) permit(s) the         alignment appendage to be forcefully separated from (broken away         from) the “main body”, when the mortar is partially set, by         using only any common, sturdy, masonry-mortar-working tool         (whether that tool has a sharp or dull edge), and whether that         common, sturdy, masonry-mortar-working tool is, for example, but         not limited to:         -   1) a mortar-working “trowel” (used to place viscous masonry             mortar on previously positioned masonry structural elements             before positioning the next additional masonry structural             element), or         -   2) a “mortar-forming tool” (used to smooth and/or give a             specific shape to that portion of the mortar “seam” lying             between adjacent masonry structural elements), and     -   (vi) in the depicted embodiment, has an optional alignment         appendage having a protrusion opposite the “main body”. The         protrusion has a hole in it. The protrusion forms what is         commonly termed a “handle” by which the Masonry Spacer and         Aligner can be grasped, manipulated and positioned, and     -   (vii) in all embodiments, the Masonry Spacer and Aligner, and         each of its component parts, is composed of any sufficiently         rigid, durable and sturdy material, including, but not limited         to, glass, ceramic, metal, plastic, carbon or any combination of         such materials. In the depicted embodiment this material is         plastic.

In the depicted embodiment, only the “main body” of the Masonry Spacer and Aligner is placed into the viscous mortar adjacent to the edge of the previously-positioned masonry structural element. The Masonry Spacer and Aligner in the depicted embodiment is positioned so that approximately one-half of the surface of the alignment appendage (which faces toward the “main body”) is physically placed outside the mortar “seam”, directly against the largest face of one masonry structural element. The opposite end of the same alignment appendage also remains outside the mortar “seam”, and actively guides, properly aligns, and properly positions the next, additional, masonry structural element while that masonry structural element is pressed into the viscous mortar.

The Masonry Spacer and Aligner is intended to be used in combination with other Masonry Spacer and Aligners for proper position and alignment of the next additional, masonry structural element added to the masonry structure (for example, but not limited to: a “wall” or “fascia”). When multiple Masonry Spacer and Aligners are used collectively on the top and the sides of previously-positioned masonry structural elements, the multiple “main bodies” (in the mortar seams) and the alignment appendages (outside the mortar seams) ensure proper spacing and rotational positioning of a newly-added masonry structural element in all six (6) dimensions.

-   -   (vii) In alternate envisioned embodiments, the optional         alignment appendage is attached to the “main body” at a single         point, or more than one point. And, in other envisioned         embodiments, the optional alignment appendage may also have one         or more protrusions formed (or attached) and/or have one or more         indentations and/or one or more holes and/or any combination of         these, by which the Masonry Spacer and Aligner can be grasped,         manipulated and positioned (commonly known as a “handle”). In         alternate embodiments omitting the alignment appendage, the         Masonry Spacer and Aligner may be placed anywhere in the viscous         mortar seam(s). The use of three (3) Masonry Spacer and Aligners         without an alignment appendage will ensure proper spacing of the         newly added masonry structural elements in one dimension and         will also provide proper rotational alignment in two dimensions.

The functionality and claim is not limited to depicted embodiments, but as examples, other conceptualized embodiments are included in this application, disclosure and claim.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of one depicted embodiment of the Masonry Spacer and Aligner.

FIG. 1A is a view of the “end shape” which forms part of the Masonry Spacer and Aligner in one depicted embodiment. FIG. 1A has a central point from which radiate multiple spokes. Spoke “end points” collectively form an overall “circumscribed virtual shape”, which, in FIG. 1A, is a square.

FIG. 2 is a side view (as viewed from the y-z-coordinate-plane), and shows an exploded view of the primary components of the Masonry Spacer and Aligner (in one depicted embodiment): the “main body” and the optional alignment appendage.

FIG. 3 shows an isometric view of multiple Masonry Spacer and Aligners (according to one depicted embodiment) placed in viscous mortar between masonry structural elements before the alignment appendages have been removed.

FIG. 3A shows a cut-away view, in the y-z-coordinate-plane, of the Masonry Spacer and Aligner (according to one depicted embodiment) properly placed within the mortar seam and where the Masonry Spacer and Aligner is separating similar masonry structural elements (concrete blocks in the figure) from one another vertically.

FIG. 4 shows one depiction in the x-y-coordinate plane, of the almost endless possible alternate embodiment “end shapes”, comprised of combinations of various linear, curvilinear, polygonal, conic section, and/or geometric shapes. It is important to note that the claim is not restricted to any single “end shape” representation. Additionally, the “circumscribed virtual shape” can be any single, multiple, or any combination of, linear, curvilinear, polygonal, conic section, and/or geometric shapes.

FIG. 5 shows other possible embodiments for the end tips of the alignment appendage as viewed in the y-z-coordinate-plane. These possible alternate embodiments shown are for example only, and the claim is not restricted to the shapes depicted.

FIG. 5A shows other possible embodiments for the optional alignment appendage as viewed in the x-y-coordinate-plane. These possible alternate embodiments shown are for example only, and the claim is not restricted to the shapes depicted.

DETAILED DESCRIPTION

Many possible embodiments are envisioned, and the claim is not limited to the embodiment(s) depicted. However, unless otherwise indicated, the following statements in the section titled “Detailed Description” apply to the depicted embodiment shown in FIG. 1.

FIG. 1 is an isometric view of the Masonry Spacer and Aligner, according to one depicted embodiment, having an “end shape” as shown in FIG. 1A, and a 3-dimensional “main body” formed by extrapolation of the “end shape” into the z-axis dimension, and having an optional alignment appendage (201).

In the depicted embodiment, the thin “ribs” (114) are formed by the extrapolation of all of the “end shape” into the z-axis dimension.

In the depicted embodiment one rib contains an optional pass-through hole (115).

The optional alignment appendage (201) in the depicted embodiment, is a rectangular solid, with a protrusion. In all embodiments employing an optional alignment appendage, the alignment appendage must be easily removable after it has properly positioned and aligned the masonry structural element. Thus, in all embodiments employing an alignment appendage, the alignment appendage is attached in such a way that it can be separated from the “main body” using only a common, sturdy, masonry-mortar-working tool.

FIG. 1A, according to the depicted embodiment of the disclosure, is a view of the “end shape” (100) which forms part of the Masonry Spacer and Aligner. The depicted embodiment of FIG. 1A has a central point (101) from which radiate multiple thin spokes similar to that identified by element number (111). Intersections of any two lines form a vertex. In the depicted embodiment of FIG. 1A there are eight vertices. In the depicted embodiment, the “end shape” has a lowest point (102), (103) and (109); and a highest point (105), (106), and (107). Line “end points” (102), (103), (104), (105), (106), (107), (108) and (109) collectively form an overall “circumscribed virtual shape”, which, in the depicted embodiment of FIG. 1A, is a square.

FIG. 2 is an exploded side view of FIG. 1 (as viewed from the y-z-coordinate-plane). FIG. 2 shows the primary component of the Masonry Spacer and Aligner: the “main body” (200) and an optional component, the alignment appendage (201). This view depicts two attachment “nubs” (202) at which the alignment appendage (201) is attached to the “main body” (200). Dashed lines indicate where the alignment appendage is attached to the “main body”. This view depicts a key element of all embodiments which include an alignment appendage—wherein the alignment appendage (201) is longer, in the y-axis-dimension, from top (204) to bottom (205) than is the length of the “main body”, in the y-axis-dimension, from its highest point (105) to its lowest point (103).

Any sufficient means of attaching the alignment appendage to the “main body” may be used—whether adhesive and/or mechanical linkage, and/or welding by any method which melts and melds a portion of the parts to be joined together.

FIG. 2 also shows the alignment appendage with a protrusion (206), which has a pass-through hole in it, on the side of the alignment appendage opposite the “main body”, and which is of sufficient size and shape to enable grasping, maneuvering and positioning the Masonry Spacer and Aligner. Such an appendage is commonly termed a “handle”.

FIG. 3 shows an isometric view of multiple Masonry Spacer and Aligners placed in viscous mortar between similar masonry structural elements—which in the depicted embodiment are concrete blocks. However, the claim is not limited to the spacing and alignment of concrete blocks. This view shows multiple “alignment appendages” (201) properly placed outside the mortar “seam” before they are removed.

When multiple (preferably, but not limited to, three) Masonry Spacer and Aligners are properly placed atop a horizontal course of previously-positioned masonry structural elements (340), and in the horizontal portion of the viscous mortar material (341) laid while the masonry structure is being constructed, and when another Masonry Spacer and Aligner is also placed in the vertical viscous mortar material (341) laid between two horizontally-adjacent masonry structural elements (340), the combined group of Masonry Spacer and Aligners quickly and accurately positions and properly aligns the newly-added masonry structural element in 6-dimensions. This proper positioning and alignment eliminates many manual steps involving the use of spacing and alignment devices.

FIG. 3A shows a cut-away view (not a sectional view), in the y-z-coordinate-plane, of the Masonry Spacer and Aligner properly placed within mortar (341), and wherein the Masonry Spacer and Aligner, in the depicted embodiment, is contacting, and properly separating, similar masonry structural elements (340) vertically. This view also shows the proper positioning of one embodiment of the alignment appendage (201) outside the mortar “seam”.

FIG. 4 shows a depiction of one “end shape”—of the almost endless possible alternate embodiment “end shapes”—which is comprised of a combination of various linear, curvilinear, polygonal, conic section, and/or geometric shapes. The embodiment of FIG. 4 has a circumscribed virtual shape of an octagon. It is important to note that the claim is not restricted to any single “end shape” representation. Additionally, the claim is not restricted to any single “circumscribed virtual shape”, which, in alternate embodiments can be any single, multiple, or any combination of, linear, curvilinear, polygonal, conic section, and/or geometric shapes.

FIG. 5 shows other possible embodiments for the “end tip” (204) of the alignment appendage (201) as viewed in the y-z-coordinate-plane. These embodiments shown are examples only, but the claim is not restricted to the end tip shapes depicted.

FIG. 5A shows other possible embodiments for the alignment appendage (201) as viewed in the x-y-coordinate-plane. The embodiments shown are examples, but the claim is not restricted to the alignment appendage shapes depicted. Note that, in alternate embodiments, the alignment appendage may have pass-through holes, and/or depressions and/or protrusions. Thus, any surface of the alignment appendage need not be smooth, flat or completely solid.

Alternate Embodiments

Any and all references, herein, to the phrase “one embodiment” or “an embodiment” or “the embodiment” should be interpreted to mean that a specific feature, characteristic, or structure described can be included in at least one embodiment, and potentially multiple embodiments, of the disclosure. When reference is made to an “embodiment” in multiple places, it should not be construed to imply that the reference is necessarily to the same embodiment. Such generality also applies to the term “implementation”.

FIG. 1 through FIG. 5A depict and illustrate some of the many possible envisioned embodiments of the Masonry Spacer and Aligner, but the Masonry Spacer and Aligner disclosure and claim is not limited to the embodiments shown.

The functionality, and the claim, is not limited to, but also encompasses: any 2-dimensional “end shape”, any part of which is, or parts of which are, extended into the 3rd dimension.

In alternate embodiments the elements comprising the main body need not be of uniform thickness in any dimension, and may vary in thickness and/or length and/or height, when measured at differing points along the z-axis dimension. Optional hole(s) in the elements of the main body and/or the optional alignment appendage may be of any number, shape(s) and/or size(s). Optional holes may be replaced with depressions and/or protrusions or any combination of hole(s), depression(s) and/or protrusion(s).

In alternate embodiments the elements of the main body form any “circumscribing virtual shape”.

The functionality, and the claim, is not limited to the depicted embodiment(s), but also includes: any shape for the main body, and when the optional alignment appendage is included, the alignment appendage can be easily detached.

And, the claim, is not limited to, but also encompasses: any shape for the optional alignment appendage.

And, the claim, is not limited to, but also encompasses: any shape for the “end tip(s)” of the optional alignment appendage.

And, the claim, is not limited to, but also encompasses any alignment-appendage-to-main-body attachment configuration, and/or attachment method which permits easy separation of the alignment appendage from the “main body”.

And, the claim, is not limited to, but also encompasses any construction method or material using any appropriate, sufficiently strong, rigid, durable material including, but not limited to: glass, ceramic, metallic, plastic, carbon, or any combination of such materials.

And, alternate embodiments may have one or more holes of any size and shape, may have no holes, or may have protrusions or indentations on the elements forming the “main body” and/or the optional alignment appendage.

And, in alternate embodiments, the “handle” of the alignment appendage may consist of one or more depression(s) and/or protrusion(s), and/or the “handle” may contain no holes, or may contain one or more hole(s) in the alignment appendage to permit grasping, maneuvering and positioning the Masonry Spacer and Aligner—either manually or with the aid of a grasping tool. 

What is claimed is:
 1. A Masonry Spacer and Aligner having many envisioned embodiments which employ a design(s) generally described by, but not limited to: (i) any 2-dimensional “end shape” (in the x-y-coordinate plane), consisting of straight or curvilinear lines, vertices, and or, other geometric shapes, including holes, or any combination of these, of any size, and where the length of the elements or the size of the shape(s) comprising the “main body”, (in the x-y-coordinate plane), defines an overall “circumscribing virtual shape”; and where the dimensions of the overall “circumscribing virtual shape” conform to the spacing recommended or required by building codes for the distance between similar masonry structural elements (for example, but not limited to: bricks, concrete blocks, and stones), and, (ii) wherein all, or part(s), of the “end shape” is extrapolated into the 3rd dimension (the z-axis) forming the “main body”, and (iii) which may, or may not, have an optional alignment appendage which is larger in at least one linear dimension (in the x-y plane), than the overall “circumscribing virtual shape”, and which may or may not contain one or more hole(s), indentation(s) or protrusion(s), or any combination of hole(s), indentation(s) or protrusion(s), and its end tips may have any constructible shape, and (iv) which has the optional alignment appendage attached, by any practical means, to the “main body” in one or more small regions, and (v) whereby the optional alignment appendage is specifically attached to the “main body” in any manner which permits easy disassociation (separation, breakage) from the “main body” using a common, sturdy, masonry-mortar-working tool, after the mortar is at least partially set, and (vi) which is, or any of its component parts are, composed of any sufficiently rigid, sturdy and durable material including, but not limited to, glass, ceramic, metallic, plastic, carbon, or any combination thereof, and (vii) where, in one or more embodiments, the optional alignment appendage may include one or more protrusion(s) and/or indentation(s) and/or hole(s) (which can be used as a “handle”) by which the Masonry Spacer and Aligner may be grasped, manipulated and positioned. 